Inflatable curtain assembly

ABSTRACT

An apparatus ( 10 ) for helping to protect an occupant of a vehicle ( 12 ) having a side structure ( 16 ) and a roof ( 18 ) comprises an inflatable vehicle occupant protection device ( 14 ). The inflatable vehicle occupant protection device ( 14 ) is inflatable away from the vehicle roof ( 18 ) into a position between the side structure ( 16 ) of the vehicle ( 12 ) and the vehicle occupant. A fill tube ( 22 ) has a portion located in the inflatable vehicle occupant protection device ( 14 ). The apparatus ( 10 ) also includes at least one support device ( 40 ) that has a portion ( 42 ) that clamps around a portion of the fill tube ( 22 ). The apparatus ( 10 ) further includes a grab handle ( 150 ) that has at least one portion ( 156 ) adapted to interconnect with the support device ( 40 ). A fastener ( 180 ) is extendable through the support device ( 40 ) to connect the grab handle ( 150 ), support device ( 40 ), fill tube ( 22 ) and inflatable vehicle occupant protection device ( 14 ) to the vehicle ( 12 ).

FIELD OF THE INVENTION

[0001] The present invention relates to an inflatable curtain that isinflatable between a side structure of a vehicle and a vehicle occupant.In particular, the present invention relates to an assembly forconnecting an inflatable curtain to a vehicle.

BACKGROUND OF THE INVENTION

[0002] It is known to inflate an inflatable curtain to help protect avehicle occupant in the event of a vehicle collision and/or a vehiclerollover. Such inflatable curtains are inflatable from the roof of thevehicle between a vehicle occupant and a side structure of the vehicle.The inflatable curtain is inflated from a deflated condition byinflation fluid directed from an inflator to the inflatable curtainthrough a fill tube.

[0003] Known inflatable curtains are stored in a folded, deflatedcondition in a housing. A support device such as a clamp or bracket isused to connect the fill tube and the inflatable curtain to the vehiclevia fasteners. It is also known to provide a grab handle in a vehicle.Known grab handles are typically connected to the vehicle via fasteners.

SUMMARY OF THE INVENTION

[0004] The present invention relates to an apparatus for helping toprotect an occupant of a vehicle that has a side structure and a roof.The apparatus includes an inflatable vehicle occupant protection devicethat is inflatable away from the vehicle roof into a position betweenthe side structure of the vehicle and the vehicle occupant. A fill tubehas a portion located in the inflatable vehicle occupant protectiondevice. The apparatus also includes at least one support device that hasa portion that clamps around a portion of the fill tube. The apparatusfurther includes a grab handle that has at least one portion adapted tointerconnect with the support device. A fastener is extendable throughthe support device to connect the grab handle, support device, fill tubeand inflatable vehicle occupant protection device to the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The foregoing and other features of the present invention willbecome apparent to one skilled in the art to which the present inventionrelates upon consideration of the following description of the inventionwith reference to the accompanying drawings, in which:

[0006]FIG. 1 is a schematic representation of a side elevation of anapparatus for helping to protect a vehicle occupant, according to thepresent invention;

[0007]FIGS. 2a and 2 b are perspective views of a support device whichforms a portion of the apparatus of FIG. 1, depicting the support devicein an open condition;

[0008]FIG. 3 is a perspective view of the support device of FIGS. 2a and2 b depicting the support device in a closed condition;

[0009]FIG. 4 is a sectional view of a portion of the apparatus of FIG. 1depicting the assembly of certain parts of the apparatus;

[0010]FIG. 5 is a sectional view of a portion of the apparatus of FIG. 1showing certain parts assembled;

[0011]FIG. 6 is an perspective view of the apparatus of FIG. 1 depictingthe assembly of the apparatus of FIG. 1;

[0012]FIG. 7 is a sectional view of a portion of the apparatus takengenerally along line 7-7 in FIG. 6, with certain parts omitted; and

[0013]FIG. 8 is a sectional view of the apparatus taken generally alongline 8-8 in FIG. 1.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0014] As representative of the present invention, an apparatus 10 helpsto protect an occupant of a vehicle 12. As shown in FIG. 1, theapparatus 10 includes an inflatable vehicle occupant protection devicein the form of an inflatable curtain 14 that is mounted adjacent theside structure 16 of the vehicle 12 and a roof 18 of the vehicle. Theside structure 16 of the vehicle 12 includes side windows 20. Aninflator 24 is connected in fluid communication with the inflatablecurtain 14 through a fill tube 22.

[0015] The fill tube 22 has a first end portion 30 for receiving fluidfrom the inflator 24. The fill tube 22 has a second end portion 32disposed in the inflatable curtain 14. The second end portion 32 of thefill tube 22 has a plurality of openings (not shown) that provide fluidcommunication between the fill tube 22 and the inflatable curtain 14.

[0016] The inflator 24 contains a stored quantity of pressurizedinflation fluid (not shown) in the form of a gas to inflate theinflatable curtain 14. The inflator 24 alternatively could contain acombination of pressurized inflation fluid and ignitable material forheating the inflation fluid, or could be a pyrotechnic inflator thatuses the combustion of gas-generating material to generate inflationfluid. As a further alternative, the inflator 24 could be of anysuitable type or construction for supplying a medium for inflating theinflatable curtain 14.

[0017] The apparatus 10 includes a housing 26 that stores the inflatablecurtain 14 in a deflated condition (not shown). The fill tube 22, thedeflated inflatable curtain 14, and housing 26 have an elongatedconfiguration and extend along the vehicle roof 18 and along the sidestructure 16 of the vehicle 12 above the side windows 20.

[0018] The vehicle 12 includes a sensor mechanism 36 (shownschematically in FIG. 1) for sensing a side impact to the vehicle 12and/or a rollover of the vehicle 12. In the event of a side impact tothe vehicle 12 of a magnitude greater than a predetermined thresholdvalue, the sensor mechanism 36 causes an electrical signal to be sentover lead wires 34 to the inflator 24. The electrical signal causes theinflator 24 to be actuated in a known manner. The inflator 24 dischargesfluid under pressure into the fill tube 22. The fill tube 22 directs thefluid into the inflatable curtain 14. The inflatable curtain 14 inflatesunder the pressure of the inflation fluid into the position of FIG. 1,between the side structure 16 of the vehicle 12 and any occupants of thevehicle 12.

[0019] The inflatable curtain 14, when inflated, extends along the sidestructure 16 of the vehicle 12 and is positioned between the sidestructure and any occupant of the vehicle. When the inflatable curtain14 is in the inflated condition, an upper edge 200 of the curtain ispositioned adjacent the intersection of the roof 18 and the sidestructure 16 of the vehicle 12. A front edge 202 of the inflatablecurtain 14 is positioned adjacent an A pillar 210 of the vehicle 12. Arear edge 204 of the inflatable curtain 14 is positioned adjacent a Cpillar 212 of the vehicle 12. The inflatable curtain 14 extends betweenthe A pillar 210 and the C pillar 212 of the vehicle 12 and overlies atleast a portion of the A pillar, C pillar, and a B pillar 214 of thevehicle.

[0020] It will be recognized by those skilled in the art that theinflatable curtain may have alternative configurations. For example, inthe illustrated embodiment, the inflatable curtain 14 extends betweenthe A pillar 210 and the C pillar 212 of the vehicle 12. The inflatablecurtain 14 could, however, extend between the A pillar 210 and the Bpillar 214 only or between the B pillar and the C pillar 212 only. Also,the inflatable curtain 14 could, when inflated, extend between the Apillar 210 and a D pillar (not shown) of the vehicle 12.

[0021] The inflatable curtain 14, when inflated, helps to protect avehicle occupant in the event of a vehicle rollover or a side impact tothe vehicle 12. The inflatable curtain 14, when inflated, helps toabsorb the energy of impacts and helps to distribute the impact energyover a large area of the curtain.

[0022] A plurality of support devices 40 connect the inflatable curtain14 and fill tube 22 to the side structure 16 of the vehicle 12. Thesupport devices 40 are operable from an open position illustrated inFIGS. 2a and 2 b to a closed position illustrated in FIG. 3 to connectthe support device to the fill tube 22. As illustrated in FIGS. 2a, 2 band 3, each support device 40 consists of a clamping portion 42 and afastening portion 44. Preferably, the support device 40 is constructedof a single piece of high-strength plastic material that is molded toform the clamping portion 42 and fastening portion 44. Those skilled inthe art, however, will recognize that alternative high-strengthmaterials, such as metal, and alternative designs, such as a multi-piececonstruction, may also be suitable for constructing the support device40. For example, the support device 40 could be formed of a single pieceof metal that is cut in a predetermined pattern and folded or bent toform the support device.

[0023] The clamping portion 42 includes an arc-shaped end portion 50 andfirst and second side walls 52 and 54 that extend from opposite ends ofthe end portion. A flat bottom portion 56 of the clamping portion 42extends generally perpendicularly from the first side wall 52 toadjacent the second side wall 54 when the support device 40 is in theclosed position of FIG. 3. The end portion 50, first and second sidewalls 52 and 54, and bottom portion 56 form an inner clamping surface 60(FIGS. 2a, 2 b and 3) of the clamping portion 42.

[0024] A first clamp flange 70 extends from the second side wall 54 in adirection perpendicular to the bottom portion 56. A second clamp flange74 extends from an end of the bottom portion 56 adjacent the second sidewall 54 of the end portion 50 in a direction perpendicular to the bottomportion. The first and second clamp flanges 70 and 74 are positioned inan adjacent and overlying relationship when the support device 40 is inthe closed position of FIG. 3.

[0025] The fastening portion 44 includes a rectangular bottom wall 80formed by the overlying first and second clamp flanges 70 and 74. Firstand second opposite side walls 82 and 84 and first and second opposingend walls 86 and 88 extend perpendicularly from the bottom wall 80 toform a chamber 90 of the support device 40. The first side wall 82 isdefined by the bottom portion 56 of the clamping portion 50. The secondside wall 84 (FIG. 2a) extends perpendicularly from the second clampflange 74 in a direction parallel to the first side wall 82. A pair ofspaced first reinforcing walls 92 extend from the fist side wall 82 tothe second side wall 84. Second reinforcing walls 94 extendperpendicularly from the first reinforcing walls 92 to the end walls 86and 88, respectively. The first reinforcing walls 92 and the first andsecond side walls 82 and 84 help define a fastener receiving chamber 100in the chamber 90.

[0026] A terminal end portion of the first clamp flange 70 forms a latchportion 102 of the support device 40. The latch portion 102 includes abase member 104 that extends generally perpendicularly from the firstclamp flange 70 and a latch member 106 that extends perpendicularly fromthe base member 104. Housing support flanges 108 extend perpendicularlyfrom longitudinal edges of the second side wall 84 in a direction awayfrom the chamber 90.

[0027] An elongated fastener opening 120 extends through the bottom wall80 of the chamber 90, i.e., through the first and second clamp flanges70 and 74. The fastener opening 120 is preferably centered between thefirst and second side walls 82 and 84 and the first and second end walls86 and 88.

[0028] As illustrated in FIG. 1, the inflatable curtain 14 includescutout portions 130 spaced along its length. Each cutout portion 130extends entirely through the inflatable curtain 14. The perimeter ofeach cutout portion 130 is sealed by means (not shown), such asstitching or an adhesive to help block leakage of inflation fluidthrough the cutout portions when the inflatable curtain 14 is inflated.

[0029] The fill tube 22 (FIGS. 4 and 5) is generally cylindrical inshape and includes a series of clamp sections 140 spaced along itslength. The cylindrical fill tube 22 is flattened on one side along theextent of each clamping section 140. Thus, the fill tube 22 has anarc-shaped portion 142 and a flat bottom portion 144 along the length ofeach clamp section 140. The spacing of the cutout portions 130 (FIG. 1)on the inflatable curtain 14 is equidistant with the spacing of theclamp sections 140 on the fill tube 22. The cutout portions 130 are thuspositioned adjacent the clamp sections 140 when the fill tube 22 isfully inserted into the inflatable curtain 14.

[0030] As illustrated in FIG. 1, the apparatus 10 also includes grabhandles 150 that are spaced apart along the length of the vehicle 12. Inthe embodiment illustrated in FIG. 1, there are two such grab handles150. One of the grab handles 150 is positioned above the forward vehicleside window 20 of the vehicle 12, and the other grab handle ispositioned above the rearward side window of the vehicle. Each grabhandle 150 (FIG. 6) has a first end 152 and an opposite second end 154.An anchor portion 156 (FIGS. 6 and 7) extends from each of the first andsecond ends 152 and 154 of the grab handle 150. Each of the anchorportions 156 include a latch portions 160 positioned near the end of theanchor portion on opposite sides of the anchor portion. As illustratedin FIG. 7, the latch portions 160 each include a guide surface 162 and alatch surface 164.

[0031] Assembly of the fill tube 22, the inflatable curtain 14, supportdevices 40, and grab handles 150 is required prior to installation inthe vehicle 12. The fill tube 22 is inserted into the inflatable curtain14. As illustrated in FIG. 4, the first and second clamp flanges 70 and74 of the support device 40 are spaced apart, thus placing the supportdevice in the open position. The clamping portion 42 of the supportdevice 40 receives the fill tube 22.

[0032] The clamp section 140 of the fill tube 22 is positioned withinthe clamping portion 42. Once the fill tube 22 is inserted into theclamping portion 42, as indicated by the dot-dash line in FIG. 4, thefirst and second clamp flanges 70 and 74 are moved together, thusplacing the support device in the closed position. This is illustratedin FIG. 5. When the support device 40 is in the closed position, thearc-shaped end portion 50 (FIG. 5) of the clamping portion 42 ispositioned adjacent the arc-shaped portion 142 of the clamp section 140.The bottom portion 56 of the clamping portion 42 is positioned adjacentthe bottom portion 144 of the clamp section 140.

[0033] When the first and second clamp flanges 70 and 74 are movedtogether, they become positioned adjacent one another. As the first andsecond clamp flanges 70 and 74 of the fastening portion 44 are drawntogether, the latch portion 102 receives a longitudinal edge 110 of thesecond clamp flange 74. The latch member 106 engages the longitudinaledge 110 of the second clamp flange 74 to lock the support device 40 inthe closed position. This causes a clamping force to be applied to thefill tube 22 by the inner clamping surface 60 of the clamping portion42. The support device 40 is thus secured to the fill tube 22. Thecutout portions 130 leave the support devices 40, particularly thechamber 90 and the fastener receiving chamber 100, unobstructed by theinflatable curtain 14.

[0034] Referring now to FIG. 8, the housing 26 is positioned around theinflatable curtain 14, fill tube 22, and support device 40. The housingsupport flanges 108 of each support device 40 engage the housing 26 andhelp to maintain its position relative to the support device 40. Thehousing 26 is cut away at locations 166 along its length. The spacing ofthe cut away locations 166 of the housing 26 is such that the fastenerreceiving chambers 100 of the support devices 40 are exposed at spacedlocations along the length of the housing. A headliner 170 of thevehicle 12 overlies the housing 26 and the support device 40, as well asthe inflatable curtain 14 and the fill tube 22.

[0035] As illustrated in FIG. 6, the first and second ends 152 and 154of the grab handles 150 are associated with respective support devices40. Referring now to FIGS. 5-7, the anchor portions 156 of the grabhandle 150 are inserted through respective apertures 172 in theheadliner 170 and extend into the fastener receiving chamber 100 of therespective support devices 40. The rectangular dimensions of the anchorportions 156 form a close fit with the rectangular dimensions of thefastener receiving chamber 100. As the anchor portions 156 are insertedinto the fastener receiving chamber 100, the guide surfaces 162 of thelatch portions 160 engage the first reinforcing side walls 92. Dependingon the dimensional tolerances between the anchor portions 156 and thefastener receiving chambers 100, this may cause the anchor portionsand/or the fastener receiving chambers 100 to deflect as the anchorportions enter the respective fastener receiving chambers.

[0036] As the anchor portions 156 are inserted into the respectivefastener receiving chambers 100, the latch portions 160 of each anchorportion reach respective dentations 174 that protrude from the firstreinforcing walls 92. The resiliency of the material used to constructthe anchor portions 156 and the support device 40 causes the latchportions 160 to “snap” around the dentations 174. The latch surfaces 164of the latch portions 160 engage the dentations 174, which helps toretain the anchor portions 156 in the fastener receiving chamber 100.The anchor portions 156 thus connect the grab handle 150 to the supportdevice 40.

[0037] As shown in FIG. 1, four support devices 40 are used to supportthe fill tube 22, inflatable curtain 14 and two grab handles 150 on thevehicle 12. Thus, in the illustrated embodiment, the apparatus 10includes four cutout portions 130, four clamping portions 140, and foursupport devices 40.

[0038] The assembled fill tube 22 (FIG. 6), inflatable curtain 14,support devices 40, and grab handles 150 are located in a desiredposition relative to the side structure 16 of the vehicle 12. Once inthe desired position, each support device 40 is fixedly connected to theside structure 16 of the vehicle 12 by a threaded fastener 180, such asa screw. As illustrated in FIGS. 6 and 8, the threaded fastener 180 isinserted into a chamber 186 in the grab handle 150, into the fastenerreceiving chamber 100, and through the fastener opening 120 in thebottom wall 80.

[0039] The fastener opening 120 is aligned with a location 182, such asan opening, in the side structure 16 of the vehicle 12 to receive thethreaded fastener 180. The location 182 may include a threaded stud 190(FIG. 8) for receiving the fastener 180. The threaded fastener 180connects the support device 40, and thus the fill tube 22, inflatablecurtain 14 and grab handles 150, to the side structure 16 of the vehicle12. When the apparatus 10 is in the position illustrated in FIG. 8,portions 184 of the grab handle 150 overlie the headliner 170. Theportions 184 impinge the headliner 170 between the grab handle 150 andthe support device 40 and between the grab handle and the housing 26 tohelp connect the headliner to the vehicle 12.

[0040] From the above description of the invention, those skilled in theart will perceive improvements, changes and modifications in theinvention. Such improvements, changes and modifications within the skillof the art are intended to be covered by the appended claims.

Having described the invention, the following is claimed:
 1. Anapparatus for helping to protect an occupant of a vehicle having a sidestructure and a roof, said apparatus comprising: an inflatable vehicleoccupant protection device inflatable away from the vehicle roof into aposition between the side structure of the vehicle and the vehicleoccupant; a fill tube having a portion located in said inflatablevehicle occupant protection device; at least one support device having aportion that clamps around a portion of said fill tube; a grab handlehaving at least one portion adapted to interconnect with said at leastone support device; and a fastener extendable through said at least onesupport device to connect said grab handle, said at least one supportdevice, said fill tube and said inflatable vehicle occupant protectiondevice to the vehicle.
 2. Apparatus as defined in claim 1, wherein saidat least one portion of said grab handle comprises an anchor portioninsertable into a fastener receiving portion of said at least onesupport device, said anchor portion including at least one latch portionthat engages said at least one support device to connect said grabhandle to said at least one support device.
 3. Apparatus as defined inclaim 2, wherein said at least one latch portion of said anchor portionextends around a dentation extending from a surface of said fastenerreceiving portion, said latch portion including a surface that engagessaid dentation to connect said grab handle to said at least one supportdevice.
 4. Apparatus as defined in claim 2, further including aheadliner overlying the roof of the vehicle between the roof and anoccupant of the vehicle, said inflatable vehicle occupant protectiondevice, said fill tube, and said at least one support device beingadapted to be positioned between the headliner and the roof of thevehicle, said anchor portions being extendable through the headlinerinto said fastener receiving portion of said at least one supportdevice.
 5. Apparatus as defined in claim 4, wherein said grab handle hasa first end and an opposite second end, said anchor portions extendingfrom said first and second ends of said grab handle in a firstdirection, parallel to each other.
 6. Apparatus as defined in claim 5,wherein said anchor portion extending from said first end of said grabhandle is insertable into a first support device and said anchor portionextending from said second end of said grab handle is insertable into asecond support device.
 7. Apparatus as defined in claim 4, wherein saidinflatable vehicle occupant protection device and said fill tube, whenconnected to the vehicle, extend along the intersection of the sidestructure of the vehicle and the vehicle roof.
 8. Apparatus as definedin claim 4, wherein said at least one support device, said grab handle,and said at least one fastener cooperate to help support the headlinerin the vehicle.
 9. Apparatus as defined in claim 1, wherein said atleast one fastener extends through said grab handle to help connect saidgrab handle to the vehicle.
 10. Apparatus as defined in claim 1, furthercomprising an inflation fluid source that provides inflation fluid forinflating said inflatable vehicle occupant protection device. 11.Apparatus as defined in claim 10, wherein said inflatable vehicleoccupant protection device is an inflatable curtain having a storedposition extending along the side structure adjacent a roof of thevehicle, said inflatable curtain being inflated away from the vehicleroof into said position between the side structure of the vehicle and avehicle occupant.
 12. Apparatus as defined in claim 11, wherein saidinflation fluid source is in fluid communication with said fill tube,said inflation fluid source, when actuated, providing inflation fluid tosaid fill tube, said fill tube directing said inflation fluid into saidinflatable curtain to inflate said inflatable curtain.
 13. Apparatus asdefined in claim 11, wherein said inflatable curtain, when inflated,extends along the side structure of the vehicle between an A pillar anda C pillar of the vehicle.
 14. Apparatus as defined in claim 2, whereinsaid inflatable curtain, when inflated, overlies at least a portion ofan A pillar, a B pillar and a C pillar of the vehicle.
 15. Apparatus asdefined in claim 2, further comprising a sensor for sensing a vehiclecondition for which deployment of said inflatable curtain is desired,said sensor actuating said inflation fluid source to provide inflationfluid to inflate said inflatable curtain.
 16. Apparatus as defined inclaim 2, wherein said inflation fluid source comprises an inflator whichis actuatable to inflate said inflatable curtain.